USOO6378265B1

(12) United States Patent (10) Patent No.: US 6,378,265 B1

Konstandt (45) Date of Patent: Apr. 30, 2002

(54) SPACE FRAME CONSTRUCTION Primary Examiner Michael Safavi

ASSEMBLY (74) Attorney, Agent, or Firm Malloy & Malloy, P.A.
(76) Inventor: Matias Konstandt, Parana 902, 1636 (57) ABSTRACT
La Lucila Buenos Aires (AR) A Space frame assembly designed for use in the constructing
(*) Notice: Subject to any disclaimer, the term of this of a variety of Substantially rigid, weight bearing Structures
patent is extended or adjusted under 35 including but not limited to walls, bridges, roof structures
U.S.C. 154(b) by 0 days. etc. The Space frame assembly comprises a plurality of
elongated preferably tubular frame members formed of a
(21) Appl. No.: 09/488,226 high Strength, light weight material having opposite end
portions formed to include an anchor portion thereon. Each
(22) Filed: Jan. 20, 2000 of Said plurality of connectors includes a base and at least
one end portion mounted thereon Such that correspondingly
Related U.S. Application Data positioned interior Surfaces of the base and end portion are
(60) Provisional application No. 60/122,118, filed on Mar. 1, disposed in confronting relation to one anther and wherein
1999.
the base and the one end portion each include a plurality of
(51) Int. Cl. ................................................ E04H 12/00 Sockets disposed in Spaced and off-set relation to one
(52) ... 52(655.2; 403/171; 403/218 another. Each of the plurality of Sockets includes an elon
(58) Field of Search ............................. 52/6.55.1, 655.2, gated curvilinear groove integrally formed therein and dis
52/81.3; 403/171, 172, 176,217, 218; 446/126 posed in aligned cooperative relation to one or more recesses
formed in the aforementioned interior Surface of the inter
(56) References Cited connected base or cover portion. The grooves and recesses
U.S. PATENT DOCUMENTS
are disposed, dimensioned and configured to receive and
grip the anchor portions on any one of the ends of any one
4.905,443 A *
3/1990 Sutcliffe et al. ........... 52?655.2 of the frame members. Interconnection of a plurality of
4,932.808 A *
6/1990 Bär et al. ...... ... 52/635.2 frame members by a plurality of connectors in an predeter
5,074,094. A *
12/1991 Gassler ...... ... 52/635.2 mined design or configuration will Serve to form a Support
5,074,700 A *
12/1991 Swoboda ...... ... 403/171 frame for any of the aforementioned Substantially rigid,
5,095,677 A *
3/1992 Godbout et al. ... 52/6.55.2 weight bearing structures of the type set forth above.
5,318,470 A * 6/1994 Denny ........................ 446/126
* cited by examiner 28 Claims, 10 Drawing Sheets
U.S. Patent Apr. 30, 2002 Sheet 1 of 10 US 6,378,265 B1
U.S. Patent Apr. 30, 2002 Sheet 2 of 10 US 6,378,265 B1

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U.S. Patent Apr. 30, 2002 Sheet 5 of 10 US 6,378,265 B1
U.S. Patent Apr. 30, 2002 Sheet 6 of 10 US 6,378,265 B1
U.S. Patent Apr. 30, 2002 Sheet 7 of 10 US 6,378,265 B1

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 US 6,378,265 B1
1 2
SPACE FRAME CONSTRUCTION
ASSEMBLY
CLAIM OF PRIORITY
The present application is based on and a claim to priority
is made under 35 U.S.C. Section 119(e) to provisional patent
application currently pending in the U.S. Patent and Trade
mark Office having Ser. No. 60/122,118 and a filing date of
Mar. 1, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a Space frame
assembly, and more in particular, to components which may
be assembled to form a Space frame assembly capable of
defining a wide variety of Structures having any one of
numerous design configurations. The Space frame assembly
of the present invention preferably comprises a plurality of
equivalently Structured and elongated frame members inter
connected by a plurality of equivalently Structured
connectors, and further, wherein any of the plurality of
frame members may be interconnected in an intended con
figuration by any of the plurality of connectors in order to
form a Support frame which may be utilized in the construc
tion of domestic or commercial buildings, bridges,
platforms, hangers, towers, panels and other Structures.
2. Description of the Related Art
The use of Support frames or assemblies of the type
referred to as “space frames' or “space framing” has been
generally known and used in the construction of a variety of
architectural and engineering Structures. Certain recognized
advantages of space frame construction include a Substan
tially equal distribution of loads and stresses throughout the
formed Structure, as well as the ability to take advantage of
the normally light-weight and high Strength material from
which Such Support frame assemblies are formed. In
addition, the resulting Structure offers a relatively unusual
appearance although one which many deem to be aestheti
cally appealing. When a Space frame Support assembly is
incorporated in the construction of various buildings or other
Structures, the above Set forth characteristics are achieved
through the use of a plurality of components, which in
general, are used repetitively to achieve a triangulated
geometry that is normally presented in a predetermined,
three dimensional, reticulated, truss-like framework. The
resulting framework is generally defined by a plurality of
interconnected Struts normally joined or attached to one
another at appropriate points, and collectively arranged to
produce the intended resulting Structure. One advantage in
utilizing Such a repetitive framework is that the various
components thereof may be mass produced in a factory, and
then easily and relatively cheaply transported to a construc
tion site where they are assembled. It has been recognized
that the Small size and light-weight material of the large
number of components comprising the Support framework
Simplifies transportation, and Supposedly, handling and con
Struction as well.
Space framing assemblies are particularly adaptable for
roof coverings and walls in that the resulting structure is
extremely rigid and has an exceptional ability to resist large,
concentrated and/or Symmetrical loads or stresses. In
addition, framework of the type set forth above is
hyperStatic, and accordingly, even when partially damaged,
due to fire, explosion, earthquake or other natural disasters,
Seldom fails or collapses totally. This feature makes Support
frames comprised of Space frame construction particularly
desirable in areas where earthquakes, hurricanes, and like
occurrences are prevalent.
In spite of the generally recognized advantages associated
with Space frame assemblies, the complexity of the various
components used in forming the truss-like framework fre
quently results in relatively high manufacturing and assem
bling costs. Therefore, the complexity of the various com
ponents may significantly limit the use of Such structures.
For these reasons, truss-like Space framing of the type
referred to above is frequently limited to the construction of
hangars, or other buildings and structures designed to
enclose a large Space, wherein the cost is closely regulated,
due to the Space framing acting as a skeleton for the
Structure. Also, Space framing is known to be utilized in the
15 construction of buildings, wherein the aesthetic and Visual
impact may be important and cost is a Secondary consider
ation.
Generally Speaking, there are two basic types of Space
frame construction previously developed and known in the
art. The first type involves the attachment of each of a
plurality of Struts to a connecting component wherein the
various Struts are joined together repetitively by bolts or like
fasteners. The connecting components are connected by and
therefore include the same number of bolts or like fasteners
25 as there are Struts being interconnected. The Second type
involves forming a Space frame assembly with the Struts and
connecting components in a two or three part Sequence,
wherein the entire connecting component is fastened to a
corresponding Strut by only a single bolt or like fastener.
However, the problems exhibited by both of these known
types of Space frame assemblies are well recognized. More
Specifically, the connecting components utilized in forming
the known types of Space frame construction generally
require the use of a large number of components, and may
35 typically include four or more cruciform clamping elements
which form the basis of the connecting components. This
Structural arrangement generally increases the manufactur
ing cost, and also, increases the possibility of errors being
made in the calculations of the amount of material needed
40 during manufacturing and the number of pieces needed
during assembly.
In order to overcome the requirement of using a large
number of fasteners with Such known assemblies and con
necting components, attempts have been made to incorpo
45 rate threaded connections to Secure the Struts to the con
necting components. However, a new set of problems arise
when the Struts are threadingly engaged with the connecting
components at the point of attachment which does not
typically occur when fasteners are used. This is due to the
50 fact that the threads typically have fine tolerances, and when
used by unskilled labor, the threads can be easily Stripped,
thereby rendering use of the connecting components impos
Sible or even dangerous should they be forced into attach
ment with one another. In addition, the threading procedure
55 is time consuming, and therefore, expensive considering the
number of components involved in the formation of a given
Structure.
In a similar but Somewhat different Space frame assembly,
connecting components have been developed which include
60 the plurality of interconnected Struts having ends which are
either flattened or bent. More importantly, it is believed that
there is a greater occurrence of failure in the extremities of
the mechanically deformed end portions of the Struts, based
primarily on the fact that Such mechanical deformation
65 weakens the Structural integrity of the entire framework.
In addition to the foregoing, others have attempted to
improve Space frame assemblies by using different kinds of
 US 6,378,265 B1
3 4
materials for the various connecting components employed
by the assembly. This Sometimes results in the generation of
galvanic corrosion between the parts formed of different
materials, which also serves to weaken the entire Structure
over a period of time. The environment and geographic
location, as well as the various weather Systems, to which
the building is exposed also have a significant effect on this
type corrosive degeneration. Also, the close tolerance
required in this type of construction has resulted in the
interconnected joints having a tendency to fuse, due to the
aforementioned galvanic corrosion after a period of time,
particularly when Subjected to a moist environment. This, in
turn, makes the Separation or detachment of individual
connecting components for purposes of removal, repair or
maintenance, extremely difficult, if not impossible. The
replacement of Such fused parts in an already completed
Structure, therefore, becomes both time consuming and
expensive. Finally, because the construction of Space frame
assemblies has historically required that a very large number
of Small, connecting components and Struts be
interconnected, which is compounded given the highly
repetitive nature of the intended geometric configuration,
manufacturing of Such components demands close toler
ances. Accordingly, the vast majority of attempts to use
Space frame construction have produced overly complex
designs resulting in laborious, time consuming assembly and
manufacture of the various components involved, thereby
increasing the resulting cost of construction to a degree
which prohibits wide spread usage of Space frame assem
blies.
SUMMARY OF THE INVENTION
The present invention is directed towards a space frame
assembly which is designed for wide spread use in that it can
be utilized to construct, both efficiently and economically, a
large variety of Substantially rigid, weight and StreSS bearing
Structures, and particularly, those of the type incorporating a
repetitive, three dimensional configuration.
More Specifically, the Space frame assembly of the present
invention comprises a plurality of improved connecting
components. In particular, the present invention includes a
plurality of improved frame members, which are preferably
both elongated, cylindrical and tubular in construction,
having oppositely disposed ends. Each of the oppositely
disposed, and preferably, open ends of each frame member
includes an anchor portion which preferably, extends later
ally outward from the cylindrical surface of the frame
member. The anchor member, in a preferred embodiment to
be described in greater detail hereinafter, is spaced at least
minimally inward from the outer eXtremity on each end of
the frame member, and includes a circular or annular con
figuration which is integrally formed on each of the ends, as
set forth above. The space frame assembly of the present
invention further comprises the interconnecting of indi
vidual ones of the plurality of frame members into a desired
three dimensional configuration, wherein the primary
“building block” of the Space frame Support assembly may
be in the form of a pyramid, defined by a base having a
Square configuration and four Sides each of which has a
triangular configuration.
The Space frame assembly of the present invention further
comprises a plurality of improved connectors for intercon
necting individual ones of the plurality of frame members.
Each one of the improved connectorS is preferably used to
interconnect two or more of the frame members. Depending
on the geometrical configuration of the intended Structure
being formed, each of the plurality of connectors may be
attached concurrently to the ends of a significant number of
Such frame members, Such as eight or more. Further, each of
the plurality of connectors preferably includes a base having
a Sidewall that defines a multi-sided, exterior Surface
configuration, which most preferably, but not necessarily, is
an octagonal configuration. More specifically, the exterior
Surface configuration of the base Side wall may comprise a
variety of multi-sided configurations other than octagonal
and may even be spherical or at least partially Spherical. The
base also preferably includes a first plurality of Sockets
formed therein, in Spaced relation to one another along the
Sidewall thereof. In addition, each of the plurality connectors
includes at least one cover portion which is preferably
attached to the base by a single bolt and receiving nut
15 fastener. Preferably, the base and the at least one cover
portion are joined together by the presence of the bolt and
nut fastener Such that the correspondingly positioned interior
Surfaces of the base and the cover portion are Secured in
confronting engagement with one another.
The at least one cover portion for the base of the con
nector also preferably includes a Side wall having an exterior
Surface configuration being multi-sided or even Spherical. In
the preferred embodiment the exterior Surface configuration
is preferably but not necessarily, an octagonal configuration.
25 Most preferably, the various faces or Segments of the Side
wall of the at least one cover portion are all arranged at a
common angular orientation relative to the Side wall of the
base. The one cover portion also preferably includes a
Second plurality of Sockets disposed in Spaced relation to
one another and formed in the sidewall of the one cover
portion. When joined, the first plurality of sockets formed in
the base and the Second plurality of Sockets formed in the
cover portion are preferably disposed in spaced, off-set
relation to one another, and further, are each sized and
35 configured to Snugly receive an end of one of the plurality
of frame members the rein. In the most preferred
embodiment, each of the first and Second plurality Sockets of
each base and each cover portion, respectively, are internally
Structured and configured to include an elongated groove,
40 which is Specifically dimensioned, configured and oriented
to receive, in a gripping fashion, at least a majority of the
anchor portion formed on each end of the plurality of frame
members. When so positioned, the frame members extend
outwardly from the plane of the sidewall segment to which
45 they are attached. In addition, each of the plurality of Sockets
of both the base and cover portion of each connector
includes an open end disposed in aligned, communicating
relation with the interior Surface of a corresponding cover
portion and base, respectively. AS Such, the anchor portion
50 formed on each end of the plurality of frame members is
disposed to be received by the elongated groove comprising
a portion of the interior Surface configuration of any one of
the first and Second plurality of Sockets in which they are
mounted. In order to further achieve a firm gripping of the
55 anchor portion of a frame member, the base and cover
portion include at least one receSS formed in the respective
interior Surfaces thereof. Each of Such recesses is disposed
in aligned relation to a correspondingly positioned one of the
first or Second plurality of Sockets, So that Secure, fixed and
60 adequately Supported gripping of either end portion of each
of the frame members may be established.
One feature of the present invention is the design and
Structure of each of the plurality of the connectors, which
allows a frame member to be maintained in a preferred
65 “pre-Set' orientation within an intended Socket in a manner
which will assure proper alignment of the frame members,
relative to the connectors, prior to fixedly attaching the base
 US 6,378,265 B1
S 6
to the one end portion through a fixed Securement of the bolt
and nut fastener. This greatly facilitates the assembly of any
intended Structure, Since an accurate “pre-Set' positioning of
the frame members relative to the connectors is accom
plished without requiring excessive handling or manipula
tion by the installing perSonnel.
In another preferred embodiment of the present invention,
each or a predetermined number of the connectors may
include a Second cover portion Secured to an opposite side
of the base. In this alternative embodiment, the base is
Specifically Structured to include oppositely disposed inte
rior Surfaces adaptable for confronting engagement with
Separate, Spaced apart but interconnected cover portions,
which may be attached to define the opposite ends of the
connector. By virtue of the base being capable of intercon
nection with a plurality of cover portions, Such as two cover
portions, a greater number of the frame members may be
attached to any connector, thereby greatly enhancing the
Versatility of three dimensional geometrical formations
which may be established through the utilization of the
Space frame assembly of the present invention.
In the manufacturing of the various components of the
Space frame assembly of the present invention, the cover
portions associated with each connector are preferably,
identically structured, and accordingly, can be either formed
by known casting or forging techniques using a single mold.
Similarly, the base of the connector is preferably equiva
lently structured for all of Such plurality of connectors, and
as Such, a Second mold conforming to the base can be
utilized in the casting or forging process. The forming of the
anchor portion on each of the two opposite ends of each of
the plurality of frame members can be formed preferably by
conventional Stamping techniques utilizing well-known,
tube forming machines. In addition, each of the connectors
and plurality of frame members can be formed from a
variety of materials, depending upon the intended use and
weight bearing capacity of the Structure being constructed,
further providing that all the components used in the for
mation of a single Structure are preferably formed of the
Same material. Such materials may be metallic, Such as, but
not limited to Steel or aluminum, or other materials Such as
plastics or composite materials, which may be specifically
molded or otherwise manufactured to accomplish the
intended purpose.
Therefore, the Space frame assembly of the present inven
tion is simplified by the improved design of the connectors
and frame members, which can be easily interconnected, and
further, disassembled, if that should be needed or desired.
The fact that interconnection of a plurality of frame mem
bers by a single connector with preferably the use of only a
Single bolt and nut or related fastener Structure is also a
distinct advantage. Once the Space frame assembly of the
present invention has been completed, the outer Surface
thereof can be covered by “skin' defined by panels utilizing
Somewhat conventional clips or fasteners to interconnect the
panels to the Space frame assembly for completion of the
intended architectural or engineering Structure.
The Space frame assembly of the present invention is
capable of being used as a primary Support frame for any of
a wide variety of engineering and/or architectural Structures,
and is characterized by Such structural features as Substantial
rigidity, Significant weight bearing capabilities and light
weight, open construction. In addition the Space frame
assembly comprises a plurality of improved connecting
components which may be interconnected in a quick and
efficient manner by Semiskilled perSonnel to form an
intended Structure having any of a large variety of possible,
three dimensional, geometrical design configurations.
Also the Space frame assembly comprises a plurality of
connecting components, all of which are preferably formed
of a common, light-weight and yet, high Strength material
resistive to corrosion, and which may be readily intercon
nected to one another to form an intended Structure, as well
as detached from one another, at least in part, for purposes
of repair and/or replacement. Further, the Space frame
assembly is designed to Serve as an internal Support frame
for a wide variety of engineering and architectural
Structures, wherein the outer Surface of Such a Support frame
may be covered by panels or other desired components using
conventional or specialized fasteners in defining an outer
“skin' of the Structure being constructed. The Space frame
assembly includes the additional feature of being formed of
15 a minimal number of different components, wherein corre
sponding ones of Such plurality of components are equiva
lently Structured and capable of being economically
manufactured, preferably in a generally Small size, So as to
also be capable of being economically transported from a
Site of manufacture to a site of assembly. Also, the Space
frame assembly which is capable of being used as a primary
Structural Support, and which comprises a plurality of
equivalently structured components which may be intercon
nected to one another into a desired three dimensional,
25 geometrical configuration utilizing a minimum number of
Substantially conventional fasteners to fixedly interconnect
corresponding ones of Such components.
These and other objects, features and advantages of the
present invention will become more clear when the drawings
as well as the detailed description are taken into consider
ation.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present
35
invention, reference should be had to the following detailed
description taken in connection with the accompanying
drawings in which:
FIG. 1 is an exploded isometric view of the various
40
components comprising the Space frame assembly of the
present invention.
FIG. 1A is an exploded isometric view of the various
components of another embodiment of the Space frame
assembly of the present invention.
45 FIG. 2 is a top isometric view in exploded form of certain
components of the embodiment of FIG. 1.
FIG. 3 is a bottom isometric view in exploded form of the
embodiment of FIG. 2.
FIG. 4 is a top isometric view in assembled form of
50 certain components of the embodiment of FIG. 1.
FIG. 5 is a bottom isometric view of the embodiment of
FIG. 4.
FIG. 6 is a Sectional view in exploded form taken along
line A-A of FIG. 1.
55
FIG. 7 is a sectional view in exploded form taken along
line B-B of FIG. 1.
FIG. 8 is a sectional view in assembled form of certain
components of the embodiment of FIG. 1.
FIG. 9 is a sectional view in assembled form of certain
60
components of the embodiment of FIG. 1.
FIG. 10 is a sectional view in assembled form of another
preferred embodiment of the present invention.
FIG. 11 is a sectional view in assembled form of another
65 orientation of the embodiment of FIG. 10.
FIG. 12 is an isometric view in exploded form of the
embodiment of FIGS. 10 and 11.
 US 6,378,265 B1
7 8
FIG. 13 is an isometric view of a plurality of the com
ponents of the embodiments of FIGS. 1 through 9 assembled
into a pyramid configuration.
FIG. 14A is an isometric view of an assembled structure
formed from the components of the embodiments of FIGS.
1 through 9.
FIG. 14B is an isometric view of another assembled
Structure formed from the components of the embodiments
of FIGS. 1 through 12.
FIG. 15, 16, and 17 are each side views in partial cutaway
of different embodiments of anchor portions which may be
formed on each of the opposite ends of a frame member
component, of the type shown in the embodiments of FIGS.
1 through 12.
Like reference numerals refer to like parts throughout the
Several views of the drawings.
DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT
The present invention is directed to a Space frame
assembly, shown at least partially assembled in a pyramid
configuration 2 of FIG. 13. Pyramid 2 may comprise at least
one primary “building block' used in the construction of a
variety of architectural and engineering Structures. The
resulting building, bridge, tower, Scaffold or other Structures
which incorporates the Space frame assembly of the present
invention, would thereby, all have the common features of
Substantial rigidity, Significant load, weight bearing and
StreSS capabilities, and further, could be formed to have an
extremely large variety of possible, three dimensional geo
metrical design configurations. More specifically, the Space
frame assembly of the present invention comprises a plu
rality of frame members 40, interconnected to one another
by a plurality of connectors 10, So as to form an intended
geometrical configuration which defines an intended
Structure, Such as, but by no means limited to a bridge, as
shown in FIG. 14-B or a variety of other structures, such as
of the type shown in FIG. 14-A.
With initial reference to FIGS. 1 through 7, the improved
connectors 10 of the present invention will now be
described. AS illustrated each of the plurality of connectors
10 includes a base 20 having a first interior surface 25 which
may be at least partially planar and a side wall, which
preferably comprises a plurality of multi-sided, Side wall
segments 20". Further, in at least one embodiment the base
20 includes a generally octagonal Side wall configuration,
defined by eight of the side wall segments 20'. It should be
emphasized, however, that a different configuration can be
utilized, wherein the number of side wall segments 20" may
vary. In addition, the base 20 includes a first plurality of
Sockets 21, which ideally, are disposed in Spaced relation to
one another, and further wherein the Sockets 21 are inte
grally formed in alternate ones of the Side walls Segments
2O.
Each of the plurality of connectors 10 also includes at
least one cover portion 30. The preferred cover portion 30
also includes an at least partially planar interior Surface 25'
and a side wall defined by a plurality of Side wall Segments
30'. While the exterior Surface configuration of side wall
Segments 30' may be at least partially Spherical, one embodi
ment of the present invention, is perhaps best illustrated in
FIG. 4, comprises the Side wall Segments 30' arranged at an
angular orientation relative to the central axis of the cover
portion 30 as well as the side wall segments 20' of the base
20. Ideally, the angular orientation of the Side wall Segments
30' is substantially forty-five (45) degrees. The specific
angular orientation of each of the Side wall segments 30' may
vary, but preferably, would vary consistently throughout
each of the connectors 10, as they should each be equiva
lently structured. The cover portion 30 also includes a
Second plurality of Sockets, 21', which may also be integrally
formed in the cover portion 30, and which extend into the
interior of the cover portion 30 through the sidewall seg
ments 30'. It is also to be emphasized that while this
embodiment of the cover portions 30 comprises an exterior
Surface configuration having a multisided, octagonal shape,
the exterior Surface configuration could vary to include four
Sides, 6 Sides or other multi-sides shape and could even
assume the curved, Spherical or at least partially Spherical
exterior Surface configuration, as Set forth above. Also, the
15 number of spaced apart sockets 21 in base 20 and/or 21" in
the cover portion 30 could vary and include six or more
Sockets.
It should be noted that the first and second plurality of
Sockets 21 and 21' are Substantially equivalently Structured
with a distinction being, as Set forth above, that the Sockets
21' of the cover portion 30, are disposed at a preferred or
predetermined angular orientation. Preferably, and as illus
trated in FIGS. 1, 2 and 5, each of the first and second
plurality of Sockets 21 and 21" also includes an elongated
25 groove 22, which may be integrally formed on the interior
Surface thereof, wherein each of the grooves 22 has an
elongated, curvilinear and preferably a substantially “U”
shaped configuration or an inverted “U” shaped
configuration, as the case may be for the base and cover
portion, respectively. Further, each of the grooves 22 pref
erably terminates at an open end, as at 22, See FIGS. 1 and
5, corresponding to the open end of each of the plurality of
sockets 21 and 21'. In addition, the grooves 22 formed in
each of the first plurality of sockets 21 of base 20 each
35 include an aperture or window 23, as best shown in FIGS.
1 and 3. Aperture 23 is disposed and configured to allow a
correspondingly positioned Segment of an anchor portion
27, to be described Subsequently herein, to protrude there
through in order to assure a firm gripping engagement
40 between the connector 10 and an end portion, 28, of a frame
member 40.
In that the end of the frame members 40 are gripped
within the grooves 22 of the cover portion 30 of the second
plurality of Sockets 21, it is a feature of the present invention
45 that the orientation of the plane defined by Such grooves 22
is at a preferred angular orientation of 45 when the length
of the frame members 40 are equivalent. However, it is
emphasized that the angular orientation of the plane of the
groves 22 of the cover portion 30 may be oriented at a
50 variety of other angles such as substantially between 45 and
33 at least partially dependent on the lengths of the frame
members 40 connected to the cover portion 30. When the
lengths of the frame members 40 are equal it is most
preferred that the grooves 22 of the cover portion 30 are
55 oriented at a Substantially 45° angle, as Set forth above.
When the frame members 40 are not equal in length the
angular orientation of grooves 22 of the cover portion 30
may vary preferably within the above indicated parameters.
Therefore, correspondingly positioned grooves 22 within
60 Sockets 21" may or may not be disposed in parallel relation
to side wall segments 30'.
With reference to FIGS. 6 and 7, other structural features
of the preferably equivalently structured connectors 10 more
preferably include the formation of a pair of recesses 26 and
65 26' in the first interior Surface 25 of base 20, at locations
thereon which are ideally disposed in aligned, direct com
munication with the open end 221 of the correspondingly
 US 6,378,265 B1
9 10
positioned Second plurality of Sockets 21" in the cover
portion 30. Similarly, in one embodiment, a plurality of
recesses 26" are formed in the second interior Surface 25' of
the cover portion 30, which ideally, are disposed in aligned,
communicating relation with correspondingly positioned
ones of the first plurality of sockets 21 formed in base 20, by
means of the open end of each of the plurality of Sockets 21,
as Set forth above. The Specific structure, dimension and
configuration of the first and Second plurality Sockets 21 and
21", as well as the elongated grooves 22 and the plurality of
recesses 26, 26' and 26' are collectively designed to corre
spond to and receive the end portions, generally indicated as
28, on each of the opposite ends of the plurality of frame
members 40, as will be explained in greater detail herein
after. It is to be noted that for purposes of clarity, the recesses
26, 26' and 26' are not shown in all the accompanying
Figures.
Referring now to FIGS. 1, and 6 through 9, when the
connector 10 is assembled to assume a fixedly connected
position, the base 20 will preferably be secured to the at least
one cover portion 30, by means of a Single fastener Structure,
50, preferably in the form of an elongated bolt or screw like
member, and a connecting Structure to the distal end thereof,
such as a nut, 51. More specifically, the fastener 50 is
preferably of sufficient length to extend co-linearly to the
central axis of both the assembled base 20 and the one cover
portion 30, and to be attached at its distal end, to the nut 51
in a conventional fashion. In order to facilitate attachment of
the elongated fastener 50 and the nut 51 to the connector 10,
apertures, as at 32 and 32', are preferably formed in the base
20 and the at least one cover portion 30, respectively, for
receipt of the head 50' of the fastener 50 and the nut 51,
respectively. It should be noted that the nut 51 may be
initially detached and applied by personnel during the
assembly of the base 20 and cover portion 30 or may be fixed
within the aperture 32' during the manufacture of the cover
portions 30 of the plurality of connectors 10.
AS Set forth above, the Space frame assembly of the
present invention further comprises a plurality of improved
frame members 40. In the preferred embodiment, each of the
frame members 40 is equivalently structured, and most
preferably, each frame member 40 comprises an elongated,
tubular configuration which is preferably, but not
necessarily, of equal length and which terminates at oppo
Sitely disposed end portions, generally indicated as 28. Each
of the frame members 40 preferably also includes an outer
cylindrical Surface 29 having a Substantially common outer
diameter along the entire length thereof, with the exception
of the provision of anchor portions 27, shown in FIGS. 2 and
3, which will now be described. Specifically, it is preferred
that each of the end portions 28 of each of the frame
members 40 include an anchor portion 27 thereon, which
may be Stamped or otherwise mechanically formed in the
manufacture of the frame member 40, to include outwardly
projecting anchor portions 27 which are ideally positioned
Substantially adjacent the extremities. 28' of the opposite end
portions 28 and in inwardly spaced relation thereto. Of
course, it is conceivable that an attachment member might
be attached to the end portion 28 of the frame member 40 to
form the anchor portion 27, which while not preferred,
should still be considered to fall within the scope and spirit
of the present invention. Also, in a most preferred
embodiment, each of the anchor portions 27 are defined by
a continuous, annular configuration extending outwardly
from the cylindrical Outer Surface 29 an equal distance along
the length of the respective anchor portions 27. Further, the
anchor portions 27 are preferably spaced inwardly from the
extremities. 28' an equal distance.
Due to the fact that each of the frame members 40 are
identically structured in the preferred embodiment, and in
particular, the Structural configuration and dimension of the
end portions 28 with the anchor portions 27 integrally
formed thereon, such frame members 40 are interchangeable
to the extent that any of the plurality of frame members 40
can be Secured to and extend outwardly from any one of the
plurality of connectors 10 comprising the base 20 and at
least one cover portion 30. More specifically, and as shown
in FIGS. 1 and 4 through 9, cooperative structuring of the
connectors 10 in relation to the plurality of frame members
40 allows for each one of the frame members 40 to pass
within the first plurality of sockets 21, by insertion through
an open end 22 of the elongated grooves 22. The coopera
15 tive configuring and dimensioning of the grooves 22 with
the interior Surface configuration of the respective Sockets or
Slot like Structures 21, will Serve to grip and more
Specifically, correctly align and position the frame members
40 in their intended orientation, even prior to the fixed
interconnection of the base 20 to the one cover portion 30.
Similarly, as shown in FIGS. 4, 5, and 7, any one of the
plurality of frame members 40 can be secured within any
one of the second plurality of sockets 21", by insertion of the
anchor portion 27 into the interior of the elongated grooves
25 22 formed in the cover portion 30 through the open end of
the grooves 22, as at 22". Again, the cooperative structuring,
configuring and dimensioning of each end portion 28 of each
of the plurality of frame members 40 will serve to align the
respective frame members 40 in their intended orientation,
prior to the fixed interconnection of the base 20 and cover
portion 30.
AS set forth above, and as best shown in FIG. 7, the base
20 of the connector 10 preferably includes a pair of recesses,
26 and 26'. The first recess 26 is preferably disposed,
35 dimensioned and configured to “grip” the extremity 28' of
the end portion 28 of the frame member 40 in supportive
engagement therewith, once the base 20 and cover portion
30 are interconnected by the fastening structure 50, 51. In
addition, the second recess 26' of the recess pair 26, 26' of
40 the base 20 is preferably disposed, dimensioned and con
figured to receive and grippingly engage a correspondingly
positioned Segment of the anchor portion 27. Similarly,
when a frame member 40 is positioned within any one of the
plurality of Sockets 21 of base 20, a correspondingly aligned
45 one of the plurality of recesses 26" formed in interior surface
25" of a cover portion 30 is disposed, configured and
dimensioned to grippingly engage a protruding Segment 27,
shown in FIG. 6, of the anchor portion 27, therein. By virtue
of the cooperative Structuring as Set forth above, each end
50 portion 28, by means of the outwardly projecting anchor
portion 27, is firmly gripped within the interior of the
connector 10 defined by the fixed attachment of a base 20
and one cover portion 30.
With regard to the embodiment of FIGS. 10, 11, and 12,
55 another preferred embodiment of the present invention is
illustrated wherein each of a plurality of connectors 10'
comprises a second cover portion 30". Preferably, the second
cover portion 30" is equivalently structured to the first or at
least one cover portion 30, which in the connector 10
60 illustrated, is connected to an opposite end of the base 20.
More specifically, as shown in FIG. 12, a second interior
Surface 25' of the Second, preferably opposite, cover portion
is disposed in confronting engagement with the correspond
ingly positioned interior surface 25" (or undersurface of the
65 base 20, not shown in FIG. 12, but which is shown in FIGS.
3, 6 and 7) of the base 20. As shown in FIGS. 10 and 11, each
of the aforementioned components of the connector 10
 US 6,378,265 B1
11
comprising the base 20, cover portion 30 and an oppositely
disposed cover portion 30" are preferably also all connected
by a Single fastener 50", having a greater longitudinal
dimension than the fastener 50, so as to extend co-linear to
the central axis of the base 20 and both cover portions 30 and
30". From the drawings illustrating this embodiment, it
should be apparent that the attachment of the base 20 with
two oppositely disposed cover portions 30 and 30" provides
even greater versatility in the geometric arrangement of the
various frame members 40, since a plurality of such frame
members 40 may extend outward from each of the cover
portions 30 and 30", and radially outward in a transverse
relation to the central axis of the base 20. It should also be
noted in these Figures that each of the plurality of frame
members 40 extends transversely outward from either the
base 20 or one of the cover portions 30 and/or 30" in a
substantially transverse orientation relative thereto. More
specifically, each of the frame members 40 is connected to
either the base 20 or one of the cover portions 30, 30" at an
orientation which is substantially transverse to the sidewall
segment from which it extends. Therefore, it should be
apparent that each of a plurality of frame members 40 may
be disposed in a wide variety of different positions and
orientations relative to the connector 10 or 10' to which they
are attached. As a result, and as emphasized above, a wide
variety of architectural and/or engineering Structures incor
porating an almost limitleSS number of repetitive, three
dimensional geometric configurations Such as those illus
trated by way of example only in FIGS. 14A and 14B, may
be accomplished. It is also important to note that each of the
large variety of Structures capable of being formed utilizing
the Space frame assembly of the present invention offer the
highly desirable characteristics of Substantial rigidity, Sig
nificant weight and/or StreSS bearing capabilities and a
light-weight, open construction appearance, as clearly
shown.
Further, the various orientations at which the plurality of
frame members 40 may be arranged relative to one another
due to the versatility of the connectors 10 and 10' is further
demonstrated in FIG. 13, wherein the plurality of intercon
nected frame members 40 and connectors 10 are used to
form a pyramid configuration 2 which, with additional
reference to FIGS. 14A and 14B, is shown as defining at
least one primary “building block” of the various structures
which may be formed by interconnecting the various com
ponents of the Space frame assembly of the present inven
tion. The versatility of the space frame assembly of the
present invention, including the plurality of equivalently
structured frame members 40 and connectors 10, is further
demonstrated by the relative positioning of the connectors
10, forming the base of the pyramid 2 being in a Substan
tially upright orientation relative to the position of the
pyramid. Also, the connector 10 defining the apex of the
pyramid is shown in an inverted configuration. It is pointed
out that when forming a more complex, detailed and repeti
tive three dimensional geometrical configuration of the type
shown in FIGS. 14A and 14B, other frame members 40
would be added to the plurality of connectors 10 of the
pyramid structure 2.
FIGS. 15, 16, and 17 show additional preferred embodi
ments of the frame members 40. In these embodiments, the
end portion, designated as 28", of the respective frame
members 40' has been modified. More specifically, FIG. 15
shows a wider, outwardly projected anchor portion 60
located at the extremity of the end portion 28" and being
integrally connected to the remainder of the frame member
40' by an inwardly directed, beveled flange 61. With refer
12
ence to FIG. 16, the end portion 28 is defined by a flange
member 62 having an outwardly directed flair, integrally
formed on the outer extremity of the end portion 28". FIG.
17 shows yet another preferred embodiment wherein the
anchor portion 64 is also integrally formed on the outer
extremity of the end portion 28" and comprises a Substan
tially continuous annular configuration.
Since many modifications, variations and changes in
detail can be made to the described preferred embodiment of
the invention, it is intended that all matters in the foregoing
description and shown in the accompanying drawings be
interpreted as illustrative and not in a limiting Sense. Thus,
the scope of the invention should be determined by the
appended claims and their legal equivalents.
15 Now that the invention has been described,
What is claimed is:
1. A Space frame assembly designed for use in the
construction of a variety of Substantially rigid, weight bear
ing Structures, Said assembly comprising:
a) a plurality of connectors and a plurality of frame
members, Said plurality of frame members intercon
nected to one another by Said plurality of connectors,
b) said plurality of frame members having an elongated
configuration terminating at oppositely disposed end
25 portions,
c) each of Said end portions dimensioned and configured
to be Secured to any one of Said plurality of connectors,
d) each of Said plurality of connectors comprising a base
portion having a first interior Surface and at least one
cover portion having a Second interior Surface,
e) said first and Second interior Surfaces disposed in
confronting engagement with one another upon attach
ment of Said base portion to Said cover portion,
35 f) a first plurality of Sockets integrally formed in Said base
portion in Spaced relation to one another along a
sidewall thereof,
g) a second plurality of Sockets integrally formed in Said
one cover portion in Spaced relation to one another
40 along a Sidewall thereof,
h) said first and Second plurality of Sockets disposed in
Spaced, offset relation to one another and each of Said
first and Second plurality of Sockets comprising an open
end disposed in confronting relation to Said Second
45 interior Surface and Said first interior Surface
respectively, and
i) each of Said first and Second plurality of Sockets
disposed and cooperatively structured with any one of
Said end portions to Secure Said frame members to any
50 of Said plurality of connectors in a transverse, Substan
tially radially outward extending orientation relative to
a respective one of Said base portion and cover portion
to which it is Secured.
2. An assembly as recited in claim 1 wherein each of Said
55 first plurality of Sockets includes a first groove formed
therein and dimensioned and configured to receive any one
of Said end portions therein.
3. An assembly as recited in claim 2 wherein Said Second
interior Surface of Said one cover portion comprises a
60 plurality of recesses each disposed in aligned relation to one
of Said first plurality of Sockets of Said base portion attached
thereto.
4. An assembly as recited in claim 3 wherein Said corre
spondingly aligned grooves in Said base portion and Said
65 plurality of recesses in Said Second interior Surface are
cooperatively disposed and Structured to grip either of Said
end portions of any one of Said frame members.
 US 6,378,265 B1
13
5. An assembly as recited in claim 4 wherein each of said
end portions includes an anchor portion extending outwardly
from Said frame member in Spaced relation to an outer
extremity of a corresponding one Said end portions.
6. An assembly as recited in claim 5 wherein said first
groove of each of Said first plurality of Sockets and a
correspondingly aligned receSS are collectively disposed and
dimensioned to receive Said anchor portion therein.
7. An assembly as recited in claim 5 wherein each of said
first plurality of grooves includes an aperture formed
therein, Said aperture disposed and dimensioned to allow
protrusion of Said anchor portion therethrough.
8. An assembly as recited in claim 2 wherein each of Said
Second plurality of Sockets includes a Second groove formed
therein and dimensioned and configured to receive either of
Said end portions therein.
9. An assembly as recited in claim 8 wherein said first
interior Surface of Said base comprises a plurality of recesses
each disposed in aligned relation to one of Said Second
plurality of Sockets of Said one cover portion attached
thereto.
10. An assembly as recited in claim 9 wherein corre
spondingly aligned Second grooves in Said one cover portion
and Said plurality of recesses in Said first interior Surface are
cooperatively disposed and Structured to grip Said end
portion.
11. An assembly as recited in claim 10 wherein each of
Said end portions includes an anchor portion extending
outwardly from Said frame member in Spaced relation to an
outer eXtremity of Said end portion.
12. An assembly as recited in claim 11 wherein Said
Second grooves and correspondingly aligned recesses in Said
first interior Surface are collectively disposed and dimen
Sioned to receive said anchor portion therein.
13. An assembly as recited in claim 12 wherein said first
interior Surface comprises a plurality of receSS pairs, each
receSS pair disposed in aligned relation to one of Said Second
plurality of Sockets of Said one cover portion.
14. An assembly as recited in claim 13 wherein a first
receSS of each receSS pair is disposed and configured to
receive an outer extremity of Said end portion and a Second
receSS of each receSS pair is disposed and configured to
receive Said anchor portion.
15. An assembly as recited in claim 1 wherein each of said
end portions of Said plurality of frame members comprises
an outwardly projecting anchor portion cooperatively
dimensioned and configured for gripped attachment within
any one of Said first and Second plurality of Sockets.
16. An assembly as recited in claim 15 wherein each of
Said first and Second plurality of Sockets comprises an
elongated groove formed therein and cooperatively config
ured to receive at least the majority of Said anchor portion of
any one of Said plurality of frame members therein.
17. An assembly as recited in claim 16 wherein said
Second interior Surface comprises a plurality of recesses
formed therein, each of Said plurality of recesses disposed in
aligned relation with one of Said first plurality of Sockets
through a correspondingly open end of each of Said plurality
of Sockets, each of Said plurality of recesses further disposed
in cooperatively aligned relation with Said groove of a
corresponding one of Said first plurality of Sockets in a
manner to receive Said anchor portion of any one of Said
frame members therein.
18. An assembly as recited in claim 17 wherein said first
interior Surface comprises a plurality of receSS pairs formed
therein in aligned relation with one of Said Second plurality
of Sockets through a corresponding open end of each of Said
Second plurality of Sockets.
14
19. An assembly as recited in claim 18 wherein a first
receSS of each receSS pair is disposed and configured to
receive an outer extremity of Said end portion of any one of
Said frame members and a Second receSS of Said receSS pair
is disposed and configured to receive Said anchor portion
therein.
20. A Space frame assembly designed for use in the
construction of a variety of Substantially rigid, weight bear
ing Structures, Said assembly comprising:
a) a plurality of connectors and a plurality of frame
members, Said plurality of frame members intercon
nected to one another by Said plurality if connectors,
b) said plurality of frame members having an elongated
configuration terminating at oppositely disposed end
15
portions,
c) each of Said end portions dimensioned and configured
to be Secured to any one of Said plurality of connectors,
d) each of Said plurality of connectors comprising a base
portion having two Spaced apart first interior Surfaces
and two cover portions each having a Second interior
Surface,
e) each of Said first interior Surfaces disposed in confront
ing engagement with Said Second interior Surface of a
different one of Said two cover portions upon attach
25 ment of Said base portion to Said two cover portions,
f) a first plurality of Sockets each including an open end
and being integrally formed in Said base portion in
Spaced relation to one another along a Sidewall thereof,
g) a second plurality of Sockets each including an open
end and being integrally formed in each of Said cover
portions in Spaced relation to one another along a
respective Sidewall thereof,
h) each open end of Said first plurality of Sockets disposed
in confronting relation to Said Second interior Surface of
35 one of Said cover portions and each open end of Said
Second plurality of Sockets disposed in confronting
relation to one of Said first interior Surfaces of Said base
portion, and
i) each of Said first and Second plurality of Sockets
40 disposed and cooperatively structured with any one of
Said end portions to Secure Said frame members to any
one of Said plurality of connectors in a transverse,
Substantially radially outward extending orientation
relative to a respective one of Said base portion and Said
45 two cover portions to which it is Secured.
21. An assembly as recited in claim 20 wherein each of
Said first plurality of Sockets includes a first groove formed
therein and dimensioned and configured to receive any one
of Said end portions therein; Said Second interior Surface of
50 at least one of Said two cover portions comprising a plurality
of recesses each of which is disposed in aligned relation to
one of Said first plurality of Sockets in Said base portion
being attached thereto.
22. An assembly as recited in claim 21 wherein Said
55 correspondingly aligned grooves in Said base portion and
Said plurality of recesses in Said Second interior Surface of at
least one of Said cover portions are cooperatively disposed
and Structured to grip either of Said end portions of any one
of Said frame members.
60 23. An assembly as recited in claim 22 wherein each of
Said end portions includes an anchor portion extending
outwardly from Said frame member in Spaced relation to an
outer extremity of a corresponding one of Said end portions,
Said first groove of each of Said first plurality of Sockets and
65 a correspondingly aligned receSS of one of Said two Second
interior Surfaces are collectively disposed and dimensioned
to receive said anchor portion therein.
 US 6,378,265 B1
15
24. An assembly as recited in claim 23 wherein each of
Said first plurality of grooves includes an aperture formed
therein, Said aperture disposed and dimensioned to allow
protrusion of Said anchor portion therethrough.
25. An assembly as recited in claim 20 wherein each of
Said plurality of frame members connected to Said base
portion are disposed in Substantially co-planer relation to
one another; each of Said plurality of frame members
connected to each of Said cover portions disposed in angular
orientation relative to Said plurality of frame members
connected to Said base portion.
26. A Space frame assembly designed for use in the
construction of of a variety of Substantially rigid, weight
bearing Structures, Said assembly comprising:
a) a plurality of connectors and a plurality of frame
members, Said plurality of frame members intercon
nected to one another by Said plurality of connectors,
b) said plurality of frame members having an elongated
configuration terminating at oppositely disposed end
portions,
c) each of Said end portions dimensioned and configured
to be Secured to any one of Said plurality of connectors,
d) each of Said plurality of connectors comprising a base
portion having a first interior Surface and at least one
cover portion having a Second interior Surface.
e) said first and Second interior Surfaces disposed in
confronting engagement with one another upon attach
ment of Said base portion to Said cover portion,
16
f) a first plurality of Sockets integrally formed in said
based portion in Spaced relation to one another along a
side wall thereof,
g) a second plurality of Sockets integrally formed in Said
one cover portion in Spaced relation to one another
along a side wall thereof,
h) said second interior Surface disposed in confronting
relation to Said first plurality of Sockets and in retaining
engagement with Said end portions disposed within
Said first plurality of Sockets, and
i) each of Said first and Second plurality of Sockets
disposed and cooperatively structured with any one of
Said end portions to Secure Said frame members to any
of Said plurality of connectors in a transverse, Substan
tially radially outward extending orientation relative to
15
a respective one of Said base portion and cover portion
to which it is Secured.
27. An assembly as recited in claim 26 wherein said
Second interior Surface of Said one cover portion comprises
a plurality of recesses formed therein, each of Said recesses
disposed in receiving, retaining engagement with one of Said
end portions disposed within Said first plurality of Sockets of
Said base portion attached to Said one cover portion.
28. An assembly as recited in claim 26 wherein said first
interior Surface is disposed in confronting relation to Said
25 Second plurality of Sockets and in retaining engagement with
Said end portions disposed within Said Second plurality of
Sockets.